Use of Filter Fan Units

Pharma Packaging

Client: Datwyler Pharma Packaging India Pvt. Ltd.
Location: Shirwal, Satara, Maharashtra, India
Industry: Pharma Packaging

Overview

Datwyler Pharma Packaging India Pvt. Ltd.’s Maharashtra facility produces medical rubber closure caps and stoppers for pharmaceutical drug delivery systems.

In this project, to achieve ISO classification of clean rooms, the facility implemented Filter Fan Units with integrated cooling coils, marking a pioneering move in the segment. This successful implementation not only delivered direct benefits but also set a precedent for a paradigm shift from conventional Air Handling systems in the industry.

Objective

An important aim of the project was to address the following client challenges:

Approach

We selected a brand of filter fan units with integrated cooling coils based on their proven performance in Europe. We evaluated the financial feasibility of importing such units and installing the system versus the cost of conventional methods, factoring in imports as well. This evaluation covered both capital and operational expenditures. We also ensured the viability of the timeline for system realization, including import time, local installation, and service support. The business case, considering all factors, was presented to, and approved by Datwyler.

Results

The project was executed with meticulous planning and attention to detail during installation. After successful commissioning and more than a year of use, the following results have been observed:

A 40% reduction in capital costs compared to conventional air handling/ducting systems.
Up to 50% reduction in electricity consumption costs compared to conventional air handling/ducting systems.
Space optimization above the ceiling due to the absence of heavy ducting systems, resulting in a reduced overall building height and increased walkable space above the ceiling.
Modularity in the classification of cleanroom was achieved. For changing the ISO classification of cleanroom, only change required is change of Filter Fan Units.
Loss of service continuity was reduced – failure of a single filter fan unit can be compensated for by other units available in each clean room. Alternatively, by having even 10% extra FFUs, near complete contingency can be obtained.

Engineering

Project management

Construction management

Commissioning qualification validation Support

Pharmaceutical

Biotechnology

Medical

Microelectronics

Food

Nanotechnology

Pharma Packaging